Safe operation of cold storage facilities - A ... - WorkSafe Victoria

Contents1 Introduction 12 Legal obligations 23 Consultation 34 Training and supervision 45 Using these guidelines 66 Building design and structure 87 Workplace layout and facilities 118 Traffic management 169 Environmental conditions 1910 Manual handling 2411 Plant (machinery and equipment) 2912 Emergency management 3513 Acknowledgements 3814 Appendices 39Appendix 1 – Process chart for the designof a safe cold storage workplace 39Appendix 2 – Wind chill program (chart) 40Appendix 3 – Operation of LPG forklifttrucks in poorly ventilated places 41Appendix 4 – Long-term fruit storage incontrolled atmosphere rooms 44Appendix 5 – Protective Clothingfor Cold Storage – A user’s guide 46Appendix 6 – Checklist– Anhydrous ammonia refrigerating systems 58WorkSafe Victoria is a trading nameof the Victorian WorkCover Authority.This publication is protected bycopyright. WorkSafe encourages thefree transfer, copying and printingof this publication if such activitiessupport the purpose and intent forwhich this publication was developed.

2.Legal obligationsThe Occupational Health and Safety (OHS) Act 2004 (S. 21) requires employers,so far as is reasonably practicable, to provide and maintain a workingenvironment that is safe and without risk to employees’ health. Part of this isproviding employees with information, instruction, training and supervision to ensurethey are able to perform their work in a safe manner and without risk to health.This duty extends to contractors and employees of the contractor. Employers andoperators of cold storage facilities should be aware they have a responsibility(S. 23) to others apart from employees.Managers of cold storage facilities – as well as employees – have prescribedindividual responsibilities (S. 25) as officers of a company (S. 144) for ensuringthe health and safety of employees and others in the workplace.The OHS Act also requires the designers of buildings and structures to design thebuilding or structure to be safe and without risks to the health of those using itas a workplace (S. 28).While the OHS Act prescribes the general principles and duty of care provisions ofVictorian health and safety legislation, there are a number of specific hazard-basedregulations (Occupational Health and Safety Regulations 2007) that requireemployers to identify and control risks, and consult with employees who are likelyto be affected by any activity that relates to their health and safety.More information: Occupational Health and Safety Act 2004Occupational Health and Safety Regulations 20072 Handbook Safe operation of cold storage facilities WorkSafe Victoria

3.ConsultationThere are specific duties within the OHS Act (Part 4) and various sections of hazardbasedregulations that require employers to consult with employees who are, or arelikely to be, affected by a range of health and safety matters. This includes identifyingor assessing hazards or risks, making decisions on how to control risks or whenchanges are proposed that may affect employee health and safety.Consultation must include independent contractors and employees of the independentcontractor/s, including labour hire employees – provided that the action or decisioninvolved is one the principal employer has, or should have, control over.In situations where health and safety representatives (HSRs) are elected byemployees to represent them, this consultation must involve the HSR (with or withoutthe involvement of the employees directly). Effective consultation between employers,employees and HSRs working within cold storage facilities is necessary to ensureworkplace hazards are identified and where possible eliminated or controlled.There are many benefits that can be gained through meaningful consultationbetween employers and employees including:• better outcomes resulting from employee input and a more comprehensiveidentification of potential workplace hazards and risk control options• ownership by employees in relation to any of the decisions that are made toeliminate or reduce risk• a more effective and efficient design and operation of plant and work processes• a better and more effective workplace layout that produces considerableefficiency gains• a healthy and safe workplace culture with a strong emphasis on cooperation, and• improved productivity and a reduction in absenteeism.It is important to recognise that effective consultation during the initial design andongoing operation of cold storage facilities will assist employers and operators. Itensures plant and equipment, as well as the structure and layout, are efficient andsuitable for the safe operation of the facility.More information: Occupational Health and Safety Act 2004Occupational Health and Safety Regulations 2007WorkSafe guidance and publicationsWorkSafe Victoria Handbook Safe operation of cold storage facilities 3

1213SubmissionsKey ProjectsThe IFPA has earned a reputation as an expertvoice in the area of reproductive and sexualhealth thanks to its excellent track record inproviding high quality medical, contraceptionand crisis pregnancy services. In 2008, theIFPA was called upon to make a submissionto the National Office for the Prevention ofDomestic, Sexual and Gender - based Violenceon the development of its national strategy. IFPArecommended the inclusion of FGM in the strategy.The integration of domestic violence and familyplanning services and research into domestic andgender-based violence was also recommended.In a submission to the Joint Committee onthe Constitutional Amendment on ChildrenIFPA highlighted the noticeable gap inconstitutional protection for the independentrights of the child and stated that it does notsupport the criminalisation of consensualsexual activity between minors.In June the IFPA made a submission to theHuman Rights Commission in relation to theThird Periodic Report of Ireland under theInternational Covenant on Civil and PoliticalRights (ICCPR). The commission was told thatthe Irish Government’s continued disregard forinternational human rights norms in its abortionpolicies has resulted in Irish women continuingto have a higher percentage of later abortions,receiving less pre-abortion and follow-upmedical care, and suffering from the stigmacreated by the criminalisation of abortion. IFPAcalled for greater access to abortion services forall women within the State, particularly whena woman’s health and well being is at risk.Other Key Submissions:» In April IFPA presented a report tothe Oireachtas Health Committeeon the need for a national screeningprogramme for cervical cancer.» Submission to Irish Aid through Dochason humanitarian policy highlighting need forimproved gender analysis, the importanceof reproductive health supplies and sexualand reproductive needs of adolescents.» IFPA was consulted by the EqualityAuthority for a background paper onstereotyping. IFPA contributions on imagesof women seeking abortion and the impactof gender stereotyping on sexual healthwere given priority in the publication.FGMOn November 25 2008, to coincide withInternational Day for the Elimination of Violenceagainst Women, Ireland was one of 15 Europeancountries to launch action plans to addressfemale genital mutilation (FGM) in their respectivecountries. This event was the culmination of yearsof hard work at the IFPA.IFPA was asked to develop a national plan toaddress FGM in Ireland by the EuroNet FGMAssociation as part of a 15-country project.To achieve this the IFPA brought together 17diverse organisations to form a steering committeeand produced this landmark plan of action.The document stressed the need for an interagencyapproach to address FGM in Ireland andset out three fundamental goals - prevention ofthe practice of FGM in Ireland, provision of qualityhealth care and support for women and girls whohave undergone FGM and contribution to theworldwide campaign to end FGM.The action plan called for:» The establishment of an inter-departmentalworking group to monitor and evaluate theprogress of the Plan of Action.» The enactment of legislation to specificallyprohibit FGM in Ireland.» Recognition that the harmful consequences ofFGM are being experienced here in Ireland.Salome Mbugua, AkiDwA, & Ifrah Ahmed, Somali Community inIreland, at the launch of the action plan74 people attended the launch, which was held inthe Irish Aid Centre on Dublin’s O’Connell Street inNovember.Drugs Conference and reportIFPA organised a two-day conference entitled“Drug Use: A Reproductive and Sexual HealthPerspective” in Dundalk in April. The firstconference of its kind in Ireland, the event soughtto provide information to medical, nursing andall other professionals working directly andindirectly with the drug using community aboutthe management of reproductive and sexualhealth issues. The conference formed part ofa larger project comprising two training coursesfocusing on the reproductive and sexual health ofthe drug using community for counsellors, youthworkers and other professionals working in thedrugs sector.IFPA ANNUAL REPORT 2008WWW.IFPA.IE

5.Using theseguidelinesHow to use these guidelinesThese guidelines have been divided into specific hazard or industry-based issues.While the following list may not cover all existing hazards or issues within cold storagefacilities, the general principles may be applied to those areas not listed in this document.The green, amber and red traffic light format will help you identify high-risk practicesand assess your workplace in order to implement safer work practices. The rationaleis simple: to reduce injury rates and compensation claims, high-risk situations mustbe addressed.Companies undertaking work practices in the RED high-risk area should be awarethat these activities may breach legislation and place the health and safety of theirworkers at risk.Where high-risk practices are used and identified in your workplace, you shouldimmediately consider practices in the GREEN low-risk column.If not practicable, you should put in place the comparable practices in the AMBERmedium-risk column. Generally, these only provide an interim solution as, in mostinstances, the GREEN solutions reflect good practice.If, however, you are able to demonstrate an appropriate risk assessment processhas been undertaken and you are able to verify the ‘reasonably practicable’ testhas been applied to the implemented controls, measures in the amber range maybe practicable.High Risk (Medium-risk) (Low-risk)The practices in thered column shouldnot be used in theworkplaces; an employerwho allows thesepractices to be used islikely to be in breach ofOHS legislation.The practices in theamber column are lesseffective in reducing riskcompared to those in thegreen column and shouldgenerally be treated asinterim solutions.The practices in thegreen column are mosteffective at reducing riskand should be regardedas the target for allworkplaces.6 Handbook Safe operation of cold storage facilities WorkSafe Victoria

5.Using these guidelinesUnacceptablerisk columnSolutionsshouldcontinueto bereviewedas higherordercontrolsbecomemorepracticableAre any solutions fromthe green columnreasonably practicablefor the workplace?(Undertake practicability test)NOImplement solutions,reduced risk columnYESImplementa solution,preferredsolutioncolumnThese guidelines apply no matter what time of day or day of week.WorkSafe Victoria Handbook Safe operation of cold storage facilities 7

6.Building designand structureThere are a number of structural design factors that should be considered when planning, designing or modifying any coldstorage facility. When planning the design specifications for a new cold storage facility or modifications to an existing facility,the owners and operators are presented with an opportunity to capitalise on past experience and ensure the design, layoutand selection/installation of plant and equipment utilises new technology to eliminate or reduce risk while at the same timeimprove productivity.The following building design factors should be considered during the design of any new cold storage facility or modificationsto any existing facility.More information: Design of a safe cold storage workplace chart (Appendix 1)Suspended ceilingsHigh risk examples Medium risk solutions Low risk solutionsInsulated ceiling spaces or cavitiesused by employees or contractors forstorage or maintenance that have:• not been designed andconstructed with safe meansof access and egress• no visible or prescribed maximumload capacity to ensure it willsupport the weight of personsand or material• no perimeter or other appropriatefall protection.Suspended ceilings and ceilingcavities that have:• appropriate means of accessto and egress from the ceiling cavity• sufficient space and lightingfor maintenance or the conduct ofother activities in the space• appropriately designated walkwaysand/or work platforms• suitable weight rating and arecapable of supporting workersand materials• capability of bearing additional loadfrom a build up of ice and water ifthe ceiling becomes wet• strategically positioned drainagepoints capable of removing any buildup of water.8 Handbook Safe operation of cold storage facilities WorkSafe Victoria

6.Building design and structureSuspended ceilings (continued)High risk examples Medium risk solutions Low risk solutionsWell designed suspended ceilingproviding a cavity space safe to accessand work in.• provisions for a hoist or othermechanical aid used for raising andlowering tools and equipment.Structural supportsHigh risk examples Medium risk solutions Low risk solutionsStructural supports or columnsthroughout buildings that:• are positioned in or adjacent tovehicle or forklift traffic areas• are not clearly visible andeasily defined• impede or restrict the movementof forklift and pedestrian traffic• increase thermal conduction.Structual supports or columns withintraffic areas that are:• painted to increase visibility• appropriately covered to reduceimpact and increase visibility.Building and structure designed ormodified to ensure:• no internal structural columnshinder or obstruct forklift or orderpicking activities• any internal structural supportsor columns positioned within thebuilding structure or racking• are insulated and heated to limitthermal conduction.WorkSafe Victoria Handbook Safe operation of cold storage facilities 9

6.Building design and structureAir flowsHigh risk examples Medium risk solutions Low risk solutionsPoor workplace design and layoutwith refrigeration plant and equipmentthat has:• unnecessarily high air velocity thatcreates high wind chill• fans directed onto employee workor traffic areas• noise levels at or above the 85dB(A)exposure standard.Design layout and selection of plantto ensure:• evaporators are positioned to reduceairflows and limit wind chill andsnow formation• there are safe and easy means ofaccess to plant for maintenance staff• air curtains or rapid roller doorsprovide warm work areas foremployees while maintaining coldenvironment for product• interlocked refrigeration fans thatstop when people are in area.Flooring systemsHigh risk examples Medium risk solutions Low risk solutionsPoor concrete flooring system designand construction resulting in:• tripping hazards created by uneven,cracked or broken concrete• excessive number, size, and positionof expansion joints• unsafe internal forklift traffic areasand roadways created by unevenfloor surface (due to number, sizeand position of expansion joints orfrost heave).Flat concrete flooring system that has:• racking system strategicallypositioned over expansion joints• metal plates fixed overexpansion joints.A well designed, constructed andmaintained concrete slab floor that:• is solidly constructed, level andfree of cracks or damage• is post-tensioned to remove needfor expansion joints• minimises the number and impactof expansion joints at design stage• has sufficient insulation witha suitable vapour barrier or sub-floorheating to prevent frost heave• is sealed to prevent or minimiseconcrete dust• has joints protected with steel angles.10 Handbook Safe operation of cold storage facilities WorkSafe Victoria

7.Workplace layoutand facilitiesWhile the design, layout and specification of cold storage facilities provides the best opportunity to design and/or engineer outthe risks to employees associated with workplace hazards, redesigning or modifying existing facilities can also be a cost-effectiveway to reduce risk. The re-design of the workplace layout and the relocation of existing amenities and facilities allow cold storagefacility owners and operators to better utilise the existing structure while reducing risk and improving product flow.Redesigning or modifying an existing facility also enables employers to add or reposition racking systems, ensure employeeamenities are strategically positioned close to work areas, and that access to these amenities does not require employees ortruck drivers to travel through forklift or vehicle traffic areas. These modifications also provide employers with an opportunityto explore the level of risk reduction and efficiency benefits associated with the introduction of the most recent and up-to-datetechnology in racking systems and traffic management.More information: AS/NZS 1680.1.2006Interior and workplace lighting – General principles and recommendationsVisibilityHigh risk examples Medium risk solutions Low risk solutionsFacility has an inadequate level ofvisibility due to:• poorly designed and positionedgeneral or task lighting in trafficor work areas• product storage that is in or acrossdesignated walkways or roadways• blind spots created by the temporaryor permanent storage of productpallets adjacent to roadways ortraffic areas• pedestrian, forklift and vehicletraffic intersections that createblind corners (e.g. ends of racking,doorways into and from trucks atloading dock).Facility has risk controls measures toimprove visibility that include:• adequate general lighting with noconsideration given to task lightingneeds or shadows created byracking, etc.• use of mirrors at blind corners• use of bollards and/or gates atpedestrian and forklift intersections,or blind corners• procedures requiring pedestrian,forklift and vehicle traffic to stopand look both ways at intersections• procedures requiring vehicles tosound horns when approachingintersections and when enteringor exiting buildings.Good visibility as a result of the designand the layout of the facility whichensures that:• adequate lighting has been designedand appropriately positioned in alltraffic and work areas• unobstructed and clear walkwaysand roadways where:- vehicles and pedestrian traffichave clear uninterrupted visibilityalong path of travel; and- layout and design of trafficand work areas eliminatespedestrian vehicle interaction(e.g. blind corners).Refer: AS/NZS 1680.1.2006Interior and workplace lighting – Generalprinciples and recommendationsWorkSafe Victoria Handbook Safe operation of cold storage facilities 11

7.Workplace layout and facilitiesAislesHigh risk examples Medium risk solutions Low risk solutionsPoor workplace design and layoutof storage and work areas due toaisles that:• are not wide enough to easily andsafely manoeuvre forklift trucks orother equipment• terminate at blind corners andintersect with roadways or forklifttraffic areas (e.g. ends of racking)• have product or material storedacross or within aisles• are used by both pedestrian andvehicular traffic at the same time• have inadequate lighting due toposition or type of lighting.Use of risk controls and proceduresfor aisles that:• allocate an aisle for order pickingor forklift use• have manually operated barriersor gates across aisles during orderpicking or use by forklifts• prescribe a three metre separationdistance between pedestrianand forklifts• prescribe that pedestrians haveright of way.Well designed layout of storage areaswith aisles that:• have sufficient and welldesigned lighting• have designated and physicallyseparate pedestrian and forklifttraffic areas (e.g. separatepicking aisles)• are wide enough to manoeuvreforklifts and pallet trucks intoposition during the placementor retrieval of product• are wide enough to allow forexpected volume of pedestrian trafficand any pedestrian carried loads• eliminate pedestrian and forkliftintersections (blind corners) at theends of racking aisles.AmenitiesHigh risk examples Medium risk solutions Low risk solutionsFacilities and amenities for employeessuch as lunch rooms, showers andtoilets that:• are not easily accessible or arelocated far away from work areas• are poorly designed, unclean and/ornot in a hygienic condition• do not have any or adequate First Aidfacilities and/or trained First Aid staff• are poorly equipped and do not haveadequate facilities for:- peak number of employees(e.g. labour hire/casuals)- truck drivers or visitors• do not have appropriate warm upfacilities that:- are suitably heated- are clean and well maintained- have suitable drying cabinetsfor employee personalprotective equipment (PPE).Facilities and amenities that are:• well designed, adequately equippedand clean• designed and equipped toaccommodate the maximumnumber of employees and visitors(e.g. truck drivers)• easily accessible from all work areas• located to eliminate or minimise anyinteraction between pedestrian andvehicle traffic• well equipped with clean andcomfortable warm up rooms• designed to allow for the storageand drying of employee PPE.Refer: Code of Practice for WorkplacesAppropriately designed and resourcedFirst Aid facilities with sufficientnumbers of trained staff who areaccessible to employees.Refer: Code of Practice for First Aidin Workplaces12 Handbook Safe operation of cold storage facilities WorkSafe Victoria

7.Workplace layout and facilitiesBattery storage and recharging areasHigh risk examples Medium risk solutions Low risk solutionsInappropriate and poorly designedbattery recharging and storageareas that:• are positioned on loading docks orhigh vehicular or forklift traffic areas• are within enclosed confinedareas/rooms with little or nonatural/mechanical ventilationto disburse or remove fumes• do not comply with theDangerous Goods (Storage &Handling) Regulations 2000• do not have enough spacefor manoeuvring and the safeoperation of lifting equipment• do not have appropriate PPE readilyavailable for employees (e.g. faceshields, gloves, aprons, boots)• do not have appropriate andeasily accessible emergencyequipment (e.g. safety showersand eyewash facilities).Appropriately designed battery storageand recharging areas that:• are naturally or mechanicallyventilated• are designed and operated inaccordance with the DangerousGoods (Storage & Handling)Regulations 2000Refer: AS 2359.6 Powered IndustrialTrucks – Part 6 Safety CodeAppropriate space, ventilation andfacilities to safely charge forklift batteries.• provide sufficient room for easyaccess and the safe use of liftingplant equipment to remove, storeand replace batteries• have batteries positionedon racks or secure charginglocations providing protectionfrom impact damage• have charging systemsdesigned and installed to suitthe cold storage environment(e.g. moisture, water)• have appropriate personal protectiveand emergency safety equipment(e.g. safety showers and eyewash facilities).Refer: AS 4775.2007 Emergencyeyewash and shower equipmentWorkSafe Victoria Handbook Safe operation of cold storage facilities 13

7.Workplace layout and facilitiesRacking systemsHigh risk examples Medium risk solutions Low risk solutionsPoorly designed racking systems that:• do not identify safe working load(Rated Load Capacity)• are not appropriately designedor manufacturedInappropriate racking used to stockproduct which is not rated, damagedand/or in poor condition.• are overloaded or exceedmanufacture specificationsAppropriately selected, well designedracking systems that:• have been specifically selected forthe purpose for which they areintended (e.g. manual order picking)• have been designed and installedto the appropriate standardsand specifications• are regularly inspected and maintained• clearly display maximum height andrated capacity (kg) limits• have appropriate levels of collisionprotection to prevent forklift damageand potential structural failure(e.g. bollards, barriers)• have design features that allow theeasy placement and secure storageof pallets and product• was designed and installed so as notto obstruct or restrict the effect ofceiling mounted sprinklers or otherfire protection systems.Refer: AS 4084 Supp 1-1993 : Steelstorage racking – Commentary(Supplement to AS 4084-1993)Product stacked haphazardly in aisles dueto a lack of suitable racking space.• exceed manufacturer’s maximumspecified height for portable racking• exceed manufacturer’s maximumstack height for stillages• are damaged or not maintained tomanufacturer specifications• are not provided with adequatecollision protection to preventdamage by forklifts• obstruct ceiling mounted sprinklersor other fire protection equipment.14 Handbook Safe operation of cold storage facilities WorkSafe Victoria

7.Workplace layout and facilitiesStaging areaHigh risk examples Medium risk solutions Low risk solutionsInadequate and poorly designedstaging areas that:• have no physical separation ofpedestrian and forklift traffic areas• have no designated area for thestorage or holding of consignments• does not have protected or clearlydefined roadways or walkways• creates blind corners through thepositioning of pallets of product nextto pedestrian forklift intersections• are crowded with not enough spacefor the number of consignments andsafe movement of pedestrianand forklift traffic.A staging area that relies on procedures,line markings and other forms ofadministrative control measures toseparate pedestrian and forklift traffic.Staging areas which are well designedand have a layout that has:• all doorways between staging areas,refrigerated trucks, cool rooms andfreezers have been designed toprevent snowing or a build up of iceon walls and floor areas• enough space to cater for largeconsignments and overflow orpeak workloads• clearly marked holding areasdefined and strictly maintained• clearly defined and protectedpedestrian walkways and work areas(e.g. physical guard railing or barriers).Clearly marked staging aisles.Dock levellers and loading rampsHigh risk examples Medium risk solutions Low risk solutionsUnsuitable and poorly designed dockareas with dock levellersor loading ramps that:• are not suitable or cannot beadjusted to enable mechanicalaids to be used during loadingand unloading• are not of sufficient size or structuralcapacity for the vehicles or theequipment being used• cannot be retracted fully when not inuse and so become a tripping hazard.Well designed dock areas with docklevellers and loading ramps that:• are suitable for the purposefor which they are intendedand regularly inspected andappropriately maintained• are of sufficient size, structuralcapacity and are adjustableenabling the use of variousmechanical aids used during theloading and unloading of trucks• provide safe same level accessto the rear of trucks• fold away to form continuoussurface with dock.WorkSafe Victoria Handbook Safe operation of cold storage facilities 15

8.TrafficmanagementThe constant movement of road transport vehicles, the operation of forklifts and othermobile plant – and the potential for interaction with pedestrians – presents significanttraffic management issues in cold storage facilities.Good traffic management is important for the safe and efficient movement ofpedestrian and vehicles in and around cold storage facilities. Both the designers andoperators of cold storage facilities have responsibilities to ensure the facility’s design,layout and operation eliminates, or reduces so far as is practicable, the risksassociated with traffic management.Working in the cold may mean that when vehicles with windscreens and pedestrianswith glasses move from one temperature to another visibility is affected by condensationon the windscreen or glasses.The cold environment and the movement of forklifts in and out of freezers may resultin floors becoming wet and slippery. A traffic management plan must ensure issues todo with visibility and wet, slippery floors, and the risks these environmental conditionspresent, are considered and addressed.Traffic management plans must be developed, implemented and regularly reviewedin consultation with employees. The consultative process can assist the coldstorage facility owner and/or operator to identify, eliminate or significantly reduceany risk created by interactions between pedestrians, forklifts or other forms ofvehicular traffic.Broader consultation with employer and employee representative bodies can alsoassist in identifying new or advanced technologies that may eliminate or reducerisk while at the same time providing operators with substantial efficiency andproductivity gains.The following examples of high risk activities and corresponding risk control solutionsare not exhaustive however they may assist the operators of cold storage facilitiesto identify and appropriately control risks associated with any interaction betweenpedestrians and vehicle traffic.More information: Australia Standard AS 4024.1WorkSafe publications: Forklift Safety Reducing the RiskSafety by Design – Eliminating manual handling injuriesin road transport16 Handbook Safe operation of cold storage facilities WorkSafe Victoria

8.Traffic managementTraffic management:High risk examples Medium risk solutions Low risk solutionsFacility does not have a trafficmanagement plan to control risksassociated with:• poorly designed pedestrian andvehicular work areas• employees and visitors (e.g. truckdrivers) having to cross vehicletraffic areas or roadways to accessamenities or facilities• inadequate lighting and poor visibility• blind corners where pedestrian andforklift or other vehicle trafficintersect (e.g. ends of racking,loading docks, doorways openingdirectly onto roadways)• vehicle and pedestrian trafficusing the same aisles, roadwaysand doorways• forklifts or other mobile plantoperating in pedestrian work areas• walkways and work areas withno physical separation betweenpedestrians and forklift andvehicle traffic• a lack of sufficient room or area tosafely manoeuvre forklifts or roadtransport vehicles.Facility relies on risk controls that:• consist solely of safe workprocedures and signage• require all those on site to wearhigh visibility clothing• require pedestrian and vehicletraffic to slow down, stop and look• require all forklifts and vehiclesapproaching intersections orentering or exiting buildings tosound their horns• prescribe separation distancesbetween pedestrian and forklift traffic• require forklifts and vehicles to giveway to pedestrians• has floor line marking to definepedestrian work areas and walkwaysfrom forklift and other vehiculartraffic areas• use bollards/gates acrosswalkways to slow and obstructpedestrian traffic• has mirrors to increase visibilityat blind corners.Good workplace design andlayout with a traffic managementplan which ensures:• the safe and efficient movementof pedestrian and vehicular traffic• facilities and amenities arestrategically positioned toeliminate pedestrian andvehicular traffic interaction• traffic and work areas have sufficientlighting and there is good visibility(e.g. street lighting at intersections)• pedestrian work areas and walkwaysare physically separated from forkliftand other vehicular traffic (e.g.elevated work areas and walkways)Innovative racking design provides safewalkways for pedestrians.• guard railing or physical barriers arepositioned out from and across thefront of pedestrian doorways leadingto internal or external roadways• protected walkways that changedirection to increase visibility atdoorways and pedestrian forkliftintersections• pedestrian walkways are suitablefor the volume of pedestrian traffic• there is sufficient space and roomto safely manoeuvre forklifts• the different characteristics, sizeand turning circles of various typesof road transport vehicles.WorkSafe Victoria Handbook Safe operation of cold storage facilities 17

8.Traffic managementForklift loading and unloadingHigh risk examples Medium risk solutions Low risk solutionsFacility has no adequate risk controlmeasures to protect people during theloading and unloading of trucks and:• allows unrestricted access to thedock area by pedestrians duringloading and unloading• has designated pedestrian walkwaysthat cross the path of reversingforklifts at blind corners (e.g. rearof trucks on dock area)• relies on signage as the only wayto warn pedestrian, forklift operatorsand truck drivers to be aware ofother traffic• relies on safe work proceduresthat require truck drivers, forkliftoperators, and pedestrians to stopand look when approachingor at intersections• does not prevent any deliberate orinadvertent movement of the truckduring loading or unloading (e.g.driver may enter cab and move truckduring loading/unloading process).Facility relies on the use of administrativerisk controls that may include:• the use of spring loaded gatesor bollards on walkways to impedepedestrian traffic and give themtime to stop and look• strategically positioned mirrors atblind corners• flashing or static lights to warnpedestrians of forklifts activity atthe rear of trucks• designated protected areas fordrivers to stand during loadingand unloading• signage used with other riskcontrol measures• safe work procedures designed toprevent the movement of trucks fromthe loading dock during loading andunloading (e.g. use of wheel chocksand the surrendering of keys).Measure to control the risks to anypedestrian traffic during the loadingand unloading of trucks on roadwaysor dock areas should ensure that:• pedestrian access to the dock areaduring any loading and unloadingof the truck by forklifts is restricted• where pedestrian walkways areacross the rear of trucks, thereare electronic sensors andinterlocked gates that preventpedestrian access during forkliftthe operation of forklifts(Reference AS 4024)• truck drivers are able to monitor andremotely supervise the loadingof trucks through the use of remotevisual and audio monitors• electronically interlocked systemsthat physically restrain trailers andprevent their deliberate orinadvertent movement from theloading dock until loading orunloading has been completed anddock doors are closed and locked• appropriately designed andpositioned signage is usedin conjunction with other riskcontrol measures.18 Handbook Safe operation of cold storage facilities WorkSafe Victoria

9.EnvironmentalconditionsWhile there are some environmental factors specific to the cold storage industry,there are other environmental hazards and risks that are well known across arange of industries and as such have prescribed standards and well documentedguidance material.Environmental hazards in the cold storage industry include:• working in cold conditions• slips, trips and falls• noise• hazardous atmospheres• lighting.In workplaces where employee exposure to cold is identified as a workplace hazardemployers must ensure appropriate risk-control measures that protect employees andensure body heat is retained have been put in place.Employers in the cold storage industry need to recognise the impact of cold stressand the potential for hypothermia, and how thermal stress may increase fatigue andaffect the ability of individual employees to work in a manner that is safe and withoutrisk to themselves and other employees.The effects a cold work environment can have on individual employees should alsobe recognised and employers should conduct regular health monitoring to ensureexposure to cold, or rapid changes in temperature, do not have an adverse impacton the health and safety of employees.Poorly ventilated spaces such as cool stores, freezer rooms and controlledatmosphere rooms may present hazardous atmospheres. A poorly ventilated spacemay become dangerous if there is an unsafe level of atmospheric contaminantsor the oxygen level is unsafe.Some examples of dangerous work in poorly ventilated places include:• liquid petroleum gas (LPG), petrol or diesel forklift trucks in cool stores or freezerrooms – dangerous levels of carbon monoxide may build up where poorly tunedLPG, petrol or diesel forklift trucks operate and ventilation is insufficient• activation of controlled atmosphere rooms used for long-term storage of fruit– the oxygen level in controlled atmosphere rooms may be as low as 2% andexposure will be life-threatening.WorkSafe Victoria Handbook Safe operation of cold storage facilities 19

9.Environmental conditionsThe following environmental hazards and the corresponding risk control measures are not exhaustive, however they may assistemployers and the operators of cold storage facilities to identify and control risks:More information: Operation of LPG forklift trucks in poorly ventilated places (Appendix 3)Long-term fruit storage in controlled atmosphere rooms (Appendix 4)Protective Clothing for Cold Storage – A Users’ Guide (Appendix 5)ColdHigh risk examples Medium risk solutions Low risk solutionsExposure of employees to the effectsof wind chill that may contribute tocold stress or hypothermia.Refer: Wind chill chart (Appendix 2)The following factors may contributeto cold stress or hypothermia:• a level of physical activity thatresults in sweating and asubsequent decrease in employeebody temperature• inadequate supply of appropriatedry protective clothing and footwear• employees with medical or otherconditions that may be affectedby cold• employees who are moresusceptible to cold stress dueto effects of drugs or alcohol• employees who are not experiencedor acclimatised to cold workenvironments are appropriatelytrained and supervised• thermal personal protective clothingand equipment that is inadequateand or poorly maintained.Administrative risk control measuresthat prescribe:• time limits for employees workingin the cold• rest periods for employees tospend in warm up rooms.The use of appropriate personalprotective equipment that is:• provided and appropriately maintained• generically issued and suitable forthe cold• supplied to employees to work inthe cold for a limited period of time(e.g. five minutes in freezer).Risk to employees from workingin the cold and their exposure tothermal stress has been eliminatedor controlled by:• using fully automated plant andequipment able to mechanicallytransfer product to and from coldstorage areas• design and layout of theworkplace and:- the selection and positioning ofrefrigeration plant and equipment- the velocity and direction of coldair from the refrigeration plantand equipment- the use of forklifts and mobileplant fitted with insulatedand heated cabins• elimination of physical activity thatmay cause sweating and a subsequentdecrease in body temperature• pre-employment medicalexaminations and health monitoringsystems are in place to ensureemployees with medical or otherconditions are not exposed to, andor affected, by the cold• individually issued and fittedpersonal protective clothing andequipment that is suitable for thecold work environment and replacedwhen wet or damaged.Refer: Protective Clothing for Cold Storage– A Users’ Guide (Appendix 5)20 Handbook Safe operation of cold storage facilities WorkSafe Victoria

9.Environmental conditionsNoise (continued)High risk examples Medium risk solutions Low risk solutions• audiometric testing for employeesexposed to noise levels that exceedthe exposure standard is conducted• employees are provided withappropriate information, instructionand training on noise and the properuse of risk control measures.Hazardous atmospheresHigh risk examples Medium risk solutions Low risk solutionsHazardous work environment createdby a carbon monoxide exhaustemmission from the use of a petrol ordiesel powered forklift truck or similarpowered plant and equipment in poorlyventilated places such as freezers,chillers and cold store rooms.Hazardous work environment createdby excessive carbon monoxideemissions from the use of LPGpowered forklift trucks or similarpowered plant in poorly ventilatedplaces such as freezers, chillers andcold store rooms.There are no adequate risk-controlmeasures in place to control the riskto employees from entering controlledatmosphere store rooms which maybe contaminated and oxygen deficient.Risk control measures and safe workprocedures for employees enteringor working in poorly ventilated placesthat include:• regular testing and monitoringof exhaust emissions from LPGpowered forklifts or similar plantoperating in poorly ventilated places• regular tuning of LPG poweredforklifts to ensure exhaust emissionsdo not exceed prescribed limits• formal recording of forkliftmaintenance including the testingand monitoring of exhaust emissions• use of mechanical ventilation toclear any carbon monoxide or otherairborne contaminant from withinthe work environment.Documented safe work procedures forthose entering or working in ControlledAtmosphere (CA) store rooms include:• appointing an authorised personresponsible for formally monitoring,recording, and controlling all accessto and from these rooms• closely supervising all employeesand all work within CA store rooms• ensuring appropriate signage isdisplayed on doors and any entrypoint into a CA store room• the provision of adequate naturalor mechanical ventilation.• Replacement of petrol, dieseland LPG forklift trucks with electricforklift trucks in all poorly ventilatedplaces (e.g. freezers, chillers, andcold storage rooms).Refer: Operation of LPG forklift trucks inpoorly ventilated places (Appendix 3)The use of remote or totally automatedmechanical risk control measures thatdoes not require anyone to enter aCA store room until the atmosphere isclear of any airborne contaminant andoxygen levels are at appropriate levels.Refer: Long-term fruit storage in controlledatmosphere rooms (Appendix 4)22 Handbook Safe operation of cold storage facilities WorkSafe Victoria

9.Environmental conditionsHazardous atmospheres (continued)High risk examples Medium risk solutions Low risk solutions• monitoring oxygen levels before andduring any entry into CA store rooms• having appropriate controlsystems capable of securelyisolating the system for chargingthe CA store room• emergency procedures for theremoval or rescue of people fromthe CA store room• adequate training of employees whomay be required to supervise orenter a CA store room.LightingHigh risk examples Medium risk solutions Low risk solutionsGeneral and task lighting at theworkplace for employees, forkliftoperators and truck drivers isinadequate and:• general and task lighting does notmeet the required lighting standards• does not provide required degreeof luminance• is not inspected and tested toensure an appropriate level ofluminance is provided and maintained• poor workplace design and layoutcreates shadows• prevents or restricts easy access tolighting for maintenance purposes.Internal and external general purposeand task lighting throughout theworkplace has been designed andinstalled to ensure that:• lighting provided is of anappropriate standard and providesadequate luminance• lighting is suitable for itsintended purpose, and can beeasily reached for maintenanceor to be replaced• where a specific or high degreeluminance is required, task andgeneral lighting is regularlyinspected and tested to ensurethe appropriate level of lightingis maintained.Refer: AS 1680.1.2006 Interior andWorkplace Lighting.WorkSafe Victoria Handbook Safe operation of cold storage facilities 23

10.Manual handlingIn the cold storage industry, musculoskeletal disorders (MSD) caused as a resultof hazardous manual handling tasks result in significant costs to the industry –in human and financial terms.Manual order picking, manual loading and unloading of road transport vehicles andcontainers result in a number of these injuries. It is recognised that cold workenvironments may increase the likelihood and the potential severity of any injury ormusculoskeletal disorder.To control the risk to employees from hazardous manual handling, employers mustconsult with employees and relevant HSRs. Consultation may involve exploringbenefits of any new technology which may be used in warehousing or other similarindustry. The selection and implementation of appropriate technology can effectivelycontrol risks associated with hazardous manual handling while at thesame time provide employers with efficiency gains and reduced costs.The key to manual order picking is to ensureemployees are able to handle items betweenshoulder and knee height at all times. This isreferred to as the Best Working Zone (BWZ),and together with ensuring that the item and isclose to their body, is the optimum position whenlifting. Items can be maintained within the BWZeither through workplace design or by usingappropriate equipment.There are a number of other factors that must beconsidered to reduce the number of injuries in coldstorage environments. These factors include thefrequency of handling, the weight and shape of theobject being lifted, the position of the object, thedistance or reach required to lift, push or pull anobject, whether handles are provided, any difficultyin handling the object (how slippery the object is),the use of gloves and any twisting of the body.GREEN - LOW RISKAMBER - MEDIUM RISKRED - HIGH RISK24 Handbook Safe operation of cold storage facilities WorkSafe Victoria

10.Manual handlingThere are other environmental factors unique to the cold storage industry that mustalso be considered to reduce the risk of MSD to employees. These environmentalfactors relate to manual handling tasks being undertaken in a cold work environmentand the accumulation of water or ice on floor surfaces that may make floors slipperyfor employees working in that environment.There are sections of the cold storage industry that have prescribed pick rates foremployees. Unreasonable work practices may increase the risk of an MSD becausethey can encourage employees to skip meal and rest breaks to meet prescribed pickrates or achieve bonus payments.Work practices that promote excessive work rates or extended shift lengths soemployees can achieve bonuses should be avoided. Senior and line managersof these facilities have prescribed responsibilities under the Occupational Healthand Safety Act 2004 either as officers of a company (S. 144) or as employees(S. 25) for ensuring the health and safety of fellow employees and others inthe work place.The Occupational Health and Safety Regulations 2007 (Part 3 – Manual Handling)require an employer to identify tasks undertaken or to be undertaken by an employeeinvolving hazardous manual handling. The employer must also ensure the risk of anMSD associated with a hazardous manual handling task is eliminated so far as isreasonably practicable. As a part of a review of a task following an MSD, it couldwell be expected that the contribution of the picking rate would be examined andpossibly modified.More information:WorkSafe publications: Code of Practice for Manual HandlingA Guide to Manual Order PickingManual Handling in the Red Meat IndustryWorkSafe Victoria Handbook Safe operation of cold storage facilities 25

10.Manual handlingOrder pickingHigh risk action Source of risk Medium risk solutions Low risk solutions• bending the back forwardor sideways more than20 degrees• twisting the back morethan 20 degrees• lifting and lowering itemsand exerting force whilein an awkward posture• exerting force while liftinglowering or twisting theback more than twicea minute• with long duration (> 30minutes continuouslyor > 2 hours over thewhole shift)• the application of highforce to lift, carry, push,pull or otherwise moveor restrain heavy loads.These actions may occurin situations listed under‘potential source of risk’or in combination withother work activities.Transferring product frompallets positioned on thefloor within a racking systemand on to pallets on the flooror lower shelves or trolleys.Picking or replenishing itemsfrom below knee height.Lifting products from belowthe knees.Repetitive picking orreplenishing items fromabove shoulder height withhigh force or long duration.Reducing risks may involvechanges to one or more ofthe following risk factors:• adjustable shelf heightsto allow employees topick from Best WorkingZone (BWZ)• height adjustable palletlifters or stands to allowemployees to stack itemsonto pallets in BWZ• pick rates that encourageemployees to take restbreaks and work safely• use of pick sticksto pull items towardsthemselves to eliminateforward reaching• plastic slip sheets orsolid top pallets toreduce resistance andthe force required whensliding items.Fully automated andcomputerised order pickingfacilities that do not requireany manual handling of items.Racking design, workplacelayout and work practicesensure that:• all order pickingundertaken ensuresemployees are alwaysworking within the BWZ.Carton live storage rackingwith no prescribed pick rates.Lifting products from abovehead height.Prescribed pick rates orbonus system encouraginghazardous manual handlingto be undertaken withoutprescribed rest or meal breaks.Well-designed rackingsystems with slip sheetsor solid based plastic palletson roller conveyor shelvingthat is sloped forward todecrease resistance andassist access to boxes at therear of the pallet.26 Handbook Safe operation of cold storage facilities WorkSafe Victoria

10.Manual handlingOrder picking (continued)High risk action Source of risk Medium risk solutions Low risk solutionsPicking is to fixed heightconveyor, adjustable heighttrolley, height adjustablepallet mover, or roll cage.Refer: WorkSafe publication,Guide to Manual Order PickingLoading & unloadingHigh risk action Source of risk Medium risk solutions Low risk solutionsApplication of high forcewhen lifting, carrying, andstacking items.Repetitive application offorce while in an awkwardposture, e.g. more thantwice a minute, or with longduration (> 30 minutescontinuously or > 2 hoursover the whole shift).These actions may occurin situations listed under‘potential source of risk’ orin combination with otherwork activities.Manually handling itemsinto or out of truck pansor containers, refrigeratedor not, including:• handling items to therear of the container ortruck pan• carrying items intoor out of containers ortruck pans• securing or releasingload binders• installing or removingfalse floors• opening or closing doors.Product items may includecarcasses, boxed cartons etc.Potential sources ofrisk include:• position of the product atpick up and at placement• work practices whereemployees do nottake prescribed mealor rest breaks• weight of the item.Reducing risk may involvechanges that may impacton the risk factors throughthe use of one or more ofthe following:• a conveyor or othermechanical aid totransfer product intoor out of truck pansor containers• a pallet lifter to presentproduct within the BWZduring manual loading orunloading from pallets• job rotation and or regularrest breaks for employeesinvolved in manualloading and unloading.Eliminate or substantiallyreduce any risk to employeeswhile loading and unloadingrefrigerated truck pans and/orcontainers employers should:• negotiate with suppliersand customers to ensurethat product is suppliedon slip sheets or palletsso any loading orunloading can beundertaken mechanically(e.g. forklift or walkiestacker), or• where manual loadingand or unloading isrequired use heightadjustable reach conveyoror similar mechanical aidsto ensure employees areworking within the BWZ.Extendable conveyor systemto assist manual loading/unloading of containersWorkSafe Victoria Handbook Safe operation of cold storage facilities 27

10.Manual handlingHandling empty palletsHigh risk action Source of risk Medium risk solutions Low risk solutionsHigh force – exertinghigh force while in anawkward posture.Removal of empty palletsManual removal of emptypallets from floor levelwithin a racking system andonto a forklift or pallet jackfor removal.Manually lifting, carrying ordragging and then stackingof empty wooden pallets.Potential source of risk:• pallets at ground level• size of pallets• weight of pallets can beup to 35 kg.Reduction of risk may involvethe use of mechanical aidsor the use of one or more ofthe following;• use hand pallet jack tomove pallets• use lighter weightsoftwood or plasticpallets, and/or• team handling of palletswithin the BWZ.Racking system, workplacedesign and layout, andwork practices for theremoval or transfer of palletsensure that;• use of a racking systemwith roller conveyorshelving capable ofdischarging empty palletsfor removal by forkliftAutomatic pallet removaltechnology.• removal, transfer, andstacking of pallets isdone mechanically or byforklift or other form ofmechanical aid• employees do notmanually handle pallets.28 Handbook Safe operation of cold storage facilities WorkSafe Victoria

11.Plant (machineryand equipment)While there are significant issues surrounding traffic management and the safeoperation of machinery and equipment in the cold storage industry, there are similarconcerns relating to the maintenance and operation of the numerous refrigerationsystems used in these workplaces.The storage and use of large quantities of anhydrous ammonia in refrigerationsystems can pose a risk to employees, adjoining premises and surroundingcommunity. The majority of risk and reported incidents where anhydrous ammoniahas been involved are attributed to poor design and installation of refrigeration plantand/or a lack of inspection and maintenance and deficiencies with the plantoperational procedures.Refrigeration plant and equipmentWhile the duties on the designers, owners and operators of cold storage facilities toensure the selection, use and maintenance of workplace plant and equipment doesnot present a risk to employees, employers must (S. 23) also ensure that otherpeople who are not employees are also not exposed to risks arising from the conductof the undertaking of the employer.This means employers must ensure that any activity or the operation of plantand equipment at the workplace does not present a risk to employees, contractorsor others.A number of incidents and inspections of cold storage facilities have raised concernsabout the safe operation and maintenance of refrigeration systems in cold storagefacilities. These concerns relate to the risks to employees, adjoining premises and thesurrounding community from the large quantities of anhydrous ammonia stored andused at the workplace. This concern, combined with lack of security at these sitescan present a significant risk to the broader community.Cold storage facilities must be proactive in the development and implementation ofpreventative maintenance programs and systems to effectively monitor and controlthe use of the plant and dangerous refrigerants.WorkSafe Victoria Handbook Safe operation of cold storage facilities 29

11.Plant (machinery and equipment)Risk control regarding refrigeration plant should take into account the following aspects:1. Design and construction of plant – the design of the refrigeration plant shouldmeet published technical standards (e.g. Australian Standards) and the plant mustbe tested (e.g. hydrostatic pressure testing and x-ray examination) in line with therequirements of the relevant standard.2. WorkSafe licensing – pressure vessels associated with the refrigeration plant mayhave to be Design Registered with WorkSafe if they are specified in Schedule 2 ofthe Occupational Health and Safety Regulations 2007. A design registrationnumber must be provided to the customer by the supplier of the vessel. Theindividual vessels may then have to be an Item of Plant Registered with WorkSafe,again if included in Schedule 2.3. Inspection and maintenance – refrigeration vessels covered by Schedule 2 arerequired to be periodically inspected (frequency of inspection as per manufacturerrecommendation or Australian Standard AS 3788:2006 Table 4.1). Ongoingpreventative maintenance must be conducted in conjunction with periodicinspection of the plant.4. Ammonia release – safe discharge of anhydrous ammonia to ensure excessrefrigerant is discharged to a safe location (e.g. not inside confined rooms butaway from employee work areas and neighbouring properties).More information:AS/NZS 1677.2:1998 Refrigerating systems – Safety requirements for fi xed applicationsAS 3788:2006 – Pressure Equipment – In service InspectionAS 3873:2001 – Pressure Equipment, Operation and MaintenanceAS 4024.1:2006 – Safety of MachineryAS 2022:2003 – Anhydrous Ammonia (Storage & Handling)Checklist – Anhydrous Ammonia Refrigeration Systems (Appendix 6)Dangerous Goods Act 1985Dangerous Goods (Storage & Handling) Regulations 200030 Handbook Safe operation of cold storage facilities WorkSafe Victoria

11.Plant (machinery and equipment)Forklifts and material handling equipmentAlthough forklifts and other forms of materials-handling equipment are extensivelyused in the cold storage industry, these items of plant type are overrepresented inthe number of workplace incidents and fatalities. As a result, WorkSafe Victoria hasdeveloped and implemented a number of compliance based initiatives that include;• a requirement for seatbelts to be retrospectively fitted to forklifts,• the compulsory use of seat belts by forklift operators, and• where there is interaction between pedestrian and forklift traffic, the developmentand implementation of an effective traffic management plan.Features now readily available and that should be considered when leasing orpurchasing forklift trucks include:• ergonomic designs, including rotating cabins for travelling in reverse and fullyadjustable tilting cabins for overhead work,• electronic interlock or pedestrian-forklift zone sensing systems that effectivelycontrol forklift movement, operate boom gates on roadways or gate locking deviceson pedestrian walkways,• insulated and heated cabins to control employee exposure to wind chill, exposure,cold stress, and the level of fatigue from working in cold environments,• air quality monitoring devices to continually monitor oxygen levels and air qualityin freezers, cold stores or other confined areas of a cold storage facility,• closed circuit television and mast mounted cameras for positioning and theretrieval of stock from the upper sections of racking, and• computerised and electronic interlock devices to ensure seatbelts are worn byoperators during forklift operation.More information:AS 4024.1 – Safety of MachineryWorkSafe publications: Forklift Safety Reducing the RiskSafety by Design – Eliminating manual handling injuriesin road transportWorkSafe Victoria Handbook Safe operation of cold storage facilities 31

11.Plant (machinery and equipment)Forklifts and mobile plantHigh risk examples Medium risk solutions Low risk solutionsInappropriate and poorlymaintained forklifts:• not fitted with seat belts• not appropriately inspectedand tested• not maintained tomanufacturer specifications• not suitable for the workbeing undertaken• have attachments that are notmatched to specific forklift• not compliant to therelevant standard• has a compliance plate that isnot authentic• operator has no forklift licence(to perform high risk work) and isnot under training and instruction• operator has no experienceoperating equipment.Cold storage facility has beenappropriately designed and uses wellmaintained battery or electric poweredforklift trucks with:• computerised automatic guidedvehicle (AGV) systems that do notrequire operators• interlocking devices to ensure thecompulsory use of seat belts• fitted electronic interlock orpedestrian or forklift zone sensingsystems that:- effectively control forklifttruck movement- operate roadway boom gatesand gate locking devices onpedestrian walkways• heated cabins designed for workin cold environments• continually monitor air quality andoxygen levels• mast mounted cameras and closedcircuit television monitors in forkliftcabins for positioning and theretrieval of stock from the uppersections of racking• automatic height levelling systemspre-programmed to racking heights• operated by competent, experiencedand licensed persons.32 Handbook Safe operation of cold storage facilities WorkSafe Victoria

11.Plant (machinery and equipment)Refrigeration plant and systemsHigh risk examples Medium risk solutions Low risk solutionsCold storage facility refrigeration plantand system is in poor condition and:• has not been installed or maintainedto the relevant standards• has piping, valves, gauges and othercomponents that are not clearlymarked and identified• pressure plant and equipment that is:- not registered with WorkSafe- not appropriately inspectedor tested by a suitablyqualified person;• there is no maintenance programto ensure the safe operation of therefrigeration plant or systems• is not operated by an appropriatelytrained and competent person• access to refrigeration plant is notsecurely restricted or appropriatelycontrolled• relief valves and discharge pipingoutlets are not appropriately locatedand are directed toward work areasor adjoining properties• there is no monitoring of therefrigeration system to detect leaks• there is no emergency managementplan to effectively control risks toemployees, adjoining premises or thelocal community.Cold storage facility has a refrigerationsystem that has:• been designed, installed, and ismaintained to the relevant standards• plant pipe work, gauges, valves andother components that are clearlylabelled and readily identified• pressure vessels registeredwith WorkSafe (applies to thosespecified in Schedule 2 of OHSRegulations 2007)• inspections and testing bya suitably qualified person• operated by a competent andexperienced person• fitted with appropriate safetyfeatures to detect and isolateany leak• an alarm or other warning device toalert the appropriate persons whenany leak is detected• appropriately located relief valvesand discharge piping outletsdirected away from work areasand adjoining properties• adequate security and restrictedaccess to areas where plant is located.Refer: Dangerous Goods Act 1985Dangerous Goods (Storage & Handling)Regulations 2000;AS 3788:2006 – Pressure Equipment– In service Inspection;AS 3873:2001 – Pressure Equipment –Operation and Maintenance.WorkSafe Victoria Handbook Safe operation of cold storage facilities 33

11.Plant (machinery and equipment)General plantHigh risk examples Medium risk solutions Low risk solutionsPlant and machinery that:• are not provided and or maintainedin a condition that is safe to use• does not have adequate guardingor suitable risk controls to preventaccess to the dangerous parts ofthe machinery during its operation• is not regularly inspected or testedto ensure that it remains safe to use• has not been designed, and/orinstalled in line with manufacturerspecifications or the appropriatestandard• does not have instructions orprocedures necessary for theinstallation, use, and maintenanceof the plant.Plant and machinery at the workplaceis selected and purchased in consultationwith employees to ensure:• all plant and equipment has beendesigned and manufactured to theappropriate standards• it is fitted with appropriate guardingto prevent access to the dangerareas of the plant or equipment• it is inspected, tested and maintainedto manufacturer specifications andthe relevant standards• employees have received adequateinformation, instruction and trainingbefore the commissioning or use ofthe plant or equipment.Refer: AS 4024.1 Safety of Machinery34 Handbook Safe operation of cold storage facilities WorkSafe Victoria

12.EmergencymanagementVarious factors must be considered by employers and operators of cold storagefacilities when determining the types of hazards and the level of risk to employees,adjoining premises and the broader community during a fire or other emergency atthe workplace.The use of styrene as an insulation material, and the volume of anhydrous ammoniaused and stored in refrigeration systems at cold storage facilities, needs to beconsidered when determining the potential type and consequence of any emergencyat the workplace.To mitigate the risks to those that may be affected by any emergency – particularlywhere substantial quantities of dangerous goods may be involved – there are prescriptiverequirements designed to identify, assess and control risks.A fire audit report is required to have been prepared and an emergency managementplan developed.Any emergency management plan must be developed in consultation withemployees, and should involve both adjoining premises or workplaces and theemergency services that may be required to respond to any emergency situationat the workplace.More information: Dangerous Goods Act 1985Dangerous Goods (Storage & Handling) Regulations 2000WorkSafe Victoria Handbook Safe operation of cold storage facilities 35

12.Emergency managementEmergency management planHigh risk examples Medium risk solutions Low risk solutionsEmergency management is inadequate:• emergency managementplan and emergency evacuationprocedures has not beendeveloped or tested• no adequate consultation with:- employees and contractors- emergency services- adjoining premisesand/or workplaces• types and potential impactof emergencies have not beenidentified or assessed• is no effective system forcommunicating with:- employees, contractors or visitorson site- adjoining premises or workplacesthat may have an impact on orbe affected by the emergency- appropriate emergency servicesIn the event of an emergencyat the workplace:• emergency services vehicles do notreceive adequate direction• access to the site or the locationof the emergency is impededor restricted• emergency assembly areas are:- not clearly marked- poorly positioned- not communicated to all thoseon site.The workplace has a formalemergency management plan andevacuation procedure:• developed and implemented inconsultation with:- employees and contractors- relevant emergency services- adjoining premisesand/or workplaces• potential emergencies identified,assessed and planned for:• consideration given to the impacton and from hazards and risks atadjoining premises• consideration given to ensureemergency services areable to respond in time• ensures is unrestricted access foremergency services• appropriate training and instructionprovided to employees and visitors(e.g. contractors and truck drivers)• there is an effective communicationsystem (e.g. public address system)to all areas of the site• emergency communication system,evacuation drills and the emergencymanagement plan is tested andreviewed regularly.Refer: Dangerous Goods Act 1985Dangerous Goods (Storage & Handling)Regulations 200036 Handbook Safe operation of cold storage facilities WorkSafe Victoria

12.Emergency managementEmergency management planHigh risk examples Medium risk solutions Low risk solutionsFacility has not provided an adequatelevel of site security and:• unrestricted access to site• no control over unauthorised accessto hazardous or high traffic areas,(eg. dock area)• unrestricted access to plant roomsand chemical and dangerous goodsstorage area.Facility developed, and implemented anappropriate level of site security:• strictly applied, monitored andregularly reviewed• effectively controls and monitors allaccess to and from the site (e.g.electronic swipe card for employees,and log in and out at security gate)• controls all access to hazardous areas(e.g. refrigeration plant, dock areas)• ensures supervisory control over allvisitors and contractors.Refer: Dangerous Goods Act 1985WorkSafe Victoria Handbook Safe operation of cold storage facilities 37

13.AcknowledgementsWorkSafe would like to acknowledge and thank the following organisations and theirindividual representatives for their valuable contribution to the development of this guide:Shaw Idea P/L and the Cold Storage Project Steering CommitteeNational Union of WorkersAustralian Metal Workers UnionAustralian Institute of Refrigeration Air-conditioning and HeatingAustralasian Meat Industry Employees UnionToyota Material Handling (Vic) P/LTransport Workers UnionDexion Australia P/LDr Andrew Baigent (Consulting Engineer)Polar Fresh Chain Services P/LColes Group LimitedVersacold Logistic LimitedRegal Cream Products P/LMcKey Distributions P/LSWIRE Cold Storage Pty. Ltd.SPC ARDMONA Operations LimitedP. Pullar & Co (Cobram) P/LAnspac Cold Storage P/LMcCain Foods (Aust) P/L38 Handbook Safe operation of cold storage facilities WorkSafe Victoria

14.AppendicesAppendix 1Design of a safe cold storage workplaceThe following chart sets out the basic steps to establish an effective design process.Getting started 1. Establish specifications that consider:1.1 Client needs (e.g. efficient product movement/throughput, sufficient storage space).1.2 Outcomes of preliminary consultation withusers and suppliers.1.3 Requirements of these guidelines, particularlythe listed design factors to be considered.Develop design 2. Develop preliminary design options forconsideration by client and users.3. Consult with client, users and suppliers.4. Determine design based on the outcomesof consultation.5. Test, refine and validate design to ensurecompliance with these guidelines.Employer to consult the relevant HSRsand workforce during the processBuild design 6. Finalise and execute design.More information: A guide to Section 28 of the Occupational Health and Safety Act 2004 – Designing Safer Buildings and StructuresWorkSafe Victoria Handbook Safe operation of cold storage facilities 39

14.AppendicesAppendix 2Wind Chill ProgramWind chill for temperatures from +5 to -20°CTair (°C)V10 5 0 -5 -10 -15 -20(km/h)5 4 -2 -7 -13 -19 -2410 3 -3 -9 -15 -21 -2715 2 -4 -11 -17 -23 -2920 1 -5 -12 -18 -24 -3025 1 -6 -12 -19 -25 -3230 0 -6 -13 -20 -26 -3335 0 -7 -14 -20 -27 -3340 -1 -7 -14 -21 -27 -3445 -1 -8 -15 -21 -28 -3550 -1 -8 -15 -22 -29 -3555 -2 -8 -15 -22 -29 -3660 -2 -9 -16 -23 -30 -3665 -2 -9 -16 -23 -30 -3770 -2 -9 -16 -23 -30 -3775 -3 -10 -17 -24 -31 -3880 -3 -10 -17 -24 -31 -38Frostbite GuideLow risk offrostbite formost peopleIncreasing risk offrostbite for mostpeople within 30minutes ofexposureHigh risk for mostpeople in 5 to10 minutes ofexposureHigh risk formost people in2 to 5 minutesof exposureHigh risk for mostpeople in 2minutes ofexposure or lessWind chill for temperatures from -25 to -50°CTair (°C)V10 -25 -30 -35 -40 -45 -50(km/h)5 -30 -36 -41 -47 -53 -5810 -33 -39 -45 -51 -57 -6315 -35 -41 -48 -54 -60 -6620 -37 -43 -49 -56 -62 -6825 -38 -44 -51 -57 -64 -7030 -39 -46 -52 -59 -65 -7235 -40 -47 -53 -60 -66 -7340 -41 -48 -54 -61 -68 -7445 -42 -48 -55 -62 -69 -7550 -42 -49 -56 -63 -69 -7655 -43 -50 -57 -63 -70 -7760 -43 -50 -57 -64 -71 -7865 -44 -51 -58 -65 -72 -7970 -44 -51 -58 -65 -72 -8075 -45 -52 -59 -66 -73 -8080 -45 -52 -60 -67 -74 -8Tair = Actual Air Temperature in °CV10 = Wind Speed at 10 metres in km/h(as reported in weather observations)Notes:1. For a given combination of temperature and windspeed, the wind chill index corresponds roughly tothe temperature that one would feel in a very lightwind. For example, a temperature of -25°C and awind speed of 20 km/h give a wind chill index of-37. This means that, with a wind of 20 km/h anda temperature of -25°C, one would feel as if it were-37°C in a very light wind.2. Wind chill does not affect objects and does notlower the actual temperature. It only describes howa human being would feel in the wind at theambient temperature.3. The wind chill index does not take into accountthe effect of sunshine. Bright sunshine may reducethe effect of wind chill (make it feel warmer) by6 to 10 units.40 Handbook Safe operation of cold storage facilities WorkSafe Victoria

14.AppendicesAppendix 3Operation of LPG forklift trucks in poorly ventilated placesIntroductionForklifts are used in many industries to handle and move materials. Petrol, diesel andliquid petroleum gas (LPG) powered forklifts emit a range of hazardous airbornecontaminants from their exhausts, including carbon monoxide (CO). LPG forkliftsgenerally have a ‘cleaner’ exhaust than petrol or diesel powered engines, yet can stillproduce dangerous levels of CO and other airborne contaminants if they are used ina poorly ventilated place, such as a cool store or freezer room.The use of poorly maintained LPG forklifts in poorly ventilated spaces posessignificant risks.The health effects of carbon monoxide (CO)CO is a colourless and odourless gas. It interferes with oxygen delivery to the tissuesin the body. The heart and the central nervous system are the main areas of the bodyaffected by CO poisoning.The early symptoms of CO poisoning include headaches and nausea. Prolongedexposure may result in dizziness, collapse, unconsciousness, coma and death. Theseverity of the effects depends on the level and length of exposure. As CO has nosmell, people exposed to high levels may have little or no warning before theycollapse. A person who has experienced a high level of exposure may sufferpermanent damage to the heart or central nervous system.Exposure standard for carbon monoxideThe Australian national exposure standard for CO is 30 parts per million (ppm)measured at the worker’s breathing zone averaged over an eight hour day (timeweighted average or (TWA)), five day working week. Those using or interpretingexposure standards should refer to the Hazardous Substances Information System(HSIS) published by Australian Safety and Compensation Council on its internet sitethat also considers short term exposure and the toxicological effects of CO.Risk control measuresTo eliminate the risk of CO poisoning, electric forklifts should be used in poorlyventilated areas. It is much safer to use electric forklifts for entry and work in poorlyventilated places such as cool stores and freezer rooms. Electric forklifts trucksshould be used in preference to petrol, diesel or LPG-powered forklift trucks in poorlyventilated places.Some workplaces use LPG forklifts in poorly ventilated places when battery poweredor electric forklifts are not available or if their use is not practicable. If LPG forklifts areused in poorly ventilated places then a high level of control needs to be in place tomake sure that employees are not exposed to a dangerous level of CO.A documented safe work practice outlining the use of LPG forklifts in poorlyventilated spaces needs to be developed and put into practice, in consultation withhealth and safety representatives. A documented safe work procedure should addressthe following points:WorkSafe Victoria Handbook Safe operation of cold storage facilities 41

14.AppendicesTuning, carburetion systems and fuel• Test the exhaust emission levels in the tail pipe of the forklift• Ensure the forklift is tuned to yield an exhaust gas containing:- not more than 0.2% (2000 ppm) CO at idling, and- not more than 0.1 % (1000 ppm) CO at speed (no load).These tuning levels are readily achievable without affecting the performance of theLPG forklift and have been widely used in Australia for several decades.• Retest and retune the forklift for CO emission:- each week until carburettor stability is known and at less frequent intervalsafter that,- if the brand or composition of the fuel changes, and- if work is carried out on the carburetion or ignition systems.• Document the results of CO emission testing and tuning. This will help toassess the ability of the forklift to hold its tune. It will also help to identify theneed for future maintenance through detecting early changes in the state of tune(maintenance on forklifts should follow the manufacturer’s recommendation).• Seek a guarantee of consistent composition of automotive grade LPG fromsuppliers. If the propane/butane ratio of LPG changes between batches this willaffect the concentration of CO emitted in the exhaust of forklifts.• Fit a stable, tamper-resistant carburetion system to the LPG forklift.• Avoid using dual fuel carburetion systems such as petrol and LPG. If dual fuelcarburetion systems are used, ensure that forklifts are powered by LPG whileentering and working in poorly ventilated places. Changing the fuel sourcebetween petrol and LPG will affect the tune of the engine, so ensure that enginesare properly tuned and tested when operated in LPG mode.• Consider fitting forklifts with a catalytic purifier to further lower CO emission.However, catalytic purifiers have little or no impact on lowering the CO emissionlevels of a forklift which is not tuned properly.Acceptable air quality• Maintain acceptable air quality when operating LPG forklifts in poorly ventilatedplaces. Use a CO gas detector to check that CO levels in the breathing zone ofemployees do not exceed the exposure standard. The CO monitor should be set toalarm at 30 ppm. CO exposure may vary from person to person depending on thesystem of work. An assessment needs to be carried out to determine the numberof CO monitors required. In some cases it may be necessary for each individualentering the cool store to be allocated or wear a CO monitor.• Use mechanical ventilation if LPG forklifts have to be used for entry for extendedperiods, such as for continuous work.Administrative controls• Ensure electric or LPG forklifts to be used in poorly ventilated places are identifiedfrom those not to be used in these areas (e.g. signage, colour).• Ensure the engine of the forklift is turned off when not in use to avoid unnecessarybuild-up of exhaust fumes.• Put emergency procedures in place which include rescue and first aid42 Handbook Safe operation of cold storage facilities WorkSafe Victoria

14.Appendices• Train employees working on tasks associated with the use of LPG forklifts inpoorly ventilated places, including:- health effects and warning signs of exposure to CO- control measures in place (including documented safe work procedures)- use of atmospheric testing equipment- what to do if the alarm on the CO monitor activates- correct tuning techniques for LPG forklifts (for mechanics).WorkSafe Victoria Handbook Safe operation of cold storage facilities 43

14.AppendicesAppendix 4Long-term fruit storage in controlled atmosphere roomsIntroductionControlled atmosphere (CA) storage is used to slow deterioration and maintain thequality of stone fruit for many months. The term CA storage means cooling to a lowtemperature and control of oxygen and carbon dioxide levels in a gas tight cool store.The oxygen concentration in the air we breathe is normally about 21%. It isconsidered safe between 19.5% and 23.5%. Typically, controlled atmosphere roomshave very low levels of oxygen, with oxygen levels around 1 to 2% during operation.These reduced levels of oxygen will result in unconsciousness without warning afterinhaling a single breath, and death within minutes. If the person survives thenpermanent brain and heart damage are likely. Rescuers spontaneously respondingto the sight of the unconscious person could also become victims.If entry and exit to an operating CA room is restricted (e.g. through a hole in ceiling)then the Confined Spaces Part of Occupational Health and Safety Regulations2007 applies.People may be at risk of exposure to an oxygen deficient atmosphere when operatingin CA rooms or working nearby. Some examples of dangerous situations are:• if a CA system is activated while a person is locked inside the room,• entering an activated CA room (Never enter an operating CA room),• when a person opens an activated CA room,• entering into a CA room which has recently been opened and is being ventilated,and• if a person is located in a poorly ventilated area next to a CA room which has beenopened and is being ventilated.Risk control measuresEntry should not be made to a CA room while it is operating.Ensure that opening and closing of CA rooms is done by a person authorisedby the employer who oversees the safe work procedures.A documented safe work practice outlining the operation of the CA room needs to bedeveloped and put into practice in consultation with health and safety representatives.A documented safe work procedure should address the following points:Closing a CA roomEnsure all people have left the CA room, close and lock the doors.• Signpost the doors with clear and prominent signs that warn people not to enterthe room (e.g. DANGER. Keep Out. Atmosphere deadly if inhaled).• Activate the CA system.Opening a CA room• Ensure the opening of the CA room is closely supervised and observed bya second person who understands and follows the safe work procedures.• Place a barricade made from cones, ropes or other portable barriers in a semicircleat least three metres from the doorway to stop unauthorised access.44 Handbook Safe operation of cold storage facilities WorkSafe Victoria

14.Appendices• Ensure people not involved with opening the doors are kept well away fromthe immediate vicinity. These persons need be instructed and trained.• Place a prominent DANGER sign alongside the portable barriers(as described above).• Record the time of opening on the sign.• Provide adequate ventilation in areas adjacent to the door before opening theCA room. If these areas are poorly ventilated or enclosed they must be barricadedto stop unauthorised access.• Unlock the door and open to its fullest extent. Ensure people openingthe room reduce their risk of exposure to an oxygen deficient atmosphere byquickly moving away from the room to a pre-identified ventilated area while thedoors are open.• Ventilate the room with fresh air until the oxygen level is at least 19.5%.Ventilation is usually carried out by opening the doors and turning on therefrigeration fans. The time taken to ventilate will vary depending on the room size,internal structure and the ventilation rate. It may assist to determine how long ittakes to ventilate the CA room. This information will help to work out the timerequired to undertake future ventilation.• Measure oxygen levels inside the room using an oxygen gas detector that iscorrectly calibrated and maintained as recommended by the manufacturer.• Measurements should be taken by a competent person who is able to follow themanufacturer’s instructions and correctly interpret the results. The tester shouldNOT enter the room while taking the measurements and the measurementsshould be taken by placing a probe into the room before the CA is activated. Theprobe should be connected to a recorder outside the room.• Declare the room safe for entry only when the oxygen level is 19.5-21%.• Record the atmospheric test results and the time the store was declared safe.• Remove portable barriers and signs and start normal work activities again.Administrative controls• Prohibit entry to a CA room while it is in operation.• Ensure the control system for the CA room is isolated so it cannot be operatedwhile people are in the cool store.• Put emergency procedures in place which include rescue and first aid.• Training for employees should include:- health effects and warning signs of oxygen deficiency,- control measures in place, including documented safe work procedures,- the use of atmospheric testing equipment, and- emergency procedures.WorkSafe Victoria Handbook Safe operation of cold storage facilities 45

14.AppendicesAppendix 5Protective Clothing for Cold Storage – A Users’ GuideProtective Clothing for Cold Storage – A Users’ GuideContentsIntroduction 46Types of cold stress 47Risk management of cold stress 47Protective clothing and equipment as a risk control 47Factors to consider when selecting personal protective equipment 53Environmental factors 53Work-related factors 54Worker-related factors 54Specific factors to consider 54Clothing 54Boots 56Gloves 57Headgear 57IntroductionA cold environment is defined as an environment under which greater than normalheat losses are anticipated and compensatory thermoregulatory actions are required.That is, attention must be paid to the heat escaping our bodies and actions taken todo something about it. Cold stress is defined as the stress resulting from the net heatloss on the body or the net heat loss on a portion of the body such as feet, hands,limbs or head.Exposure to cold environments may produce shivering, vasoconstriction, increasedoxygen consumption, accelerated respiration and pulse rate, elevated blood pressureand a significant increase in cardiac output. Severe or prolonged exposure to coldmay result in cerebral blood flow, effects on the central nervous system and mayaffect renal and liver function. In the event of abnormal reduction in core bodytemperature, hypothermia – a life threatening condition – may result. The rangeof acceptable deep core temperature variation for workers exposed to cold is verysmall with an allowable change of only + or – .1 to .4° of the normal body temperatureof 37.6°.Recognising cold stress and hypothermia as a workplace health risk is important inestablishing the required controls to prevent serious injury or illness.46 Handbook Safe operation of cold storage facilities WorkSafe Victoria

14.AppendicesTypes of Cold Stress• whole-body cooling• local cooling, including extremity cooling, convective skin cooling (wind chill),conductive skin cooling (contact cooling) and cooling of respiratory tract.Most likely, several if not all of these may be present at the same time.Classification of cold workTemperature Type of work Type of cold stress10° to 20° Sedentary, light work, finemanual work0° to10° Sedentary and stationary,light work-10° to 0° Light physical work, handlingtools and materials-20° to -10° Moderate activity, handlingmetals and fluids (petrol, etc.),windy conditionsWhole-body cooling, extremitycoolingWhole-body cooling, extremitycoolingWhole-body cooling, extremitycooling, contact coolingWhole-body cooling, extremitycooling, contact cooling,convective coolingBelow -20° All types of work All types of cold stressRisk management of cold stressThe Occupational Health and Safety Act 2004 requires risks to health and safetybe controlled so far as is reasonably practicable. This means that employers needto identify, assess and consider risk controls which eliminate the hazard at its sourceas the primary form of risk control. If the hazard is unable to be eliminated, engineeredout or the hazardous task, object, substance, etc. substituted with something saferthen, only then, can personal protective equipment be used as a form of risk control.Protective clothing and equipment as a risk controlProtective clothing and equipment is a common risk control for employees exposed tocold environments. However, it is not a good idea to rely solely on protective clothingand equipment to control risk as it may not properly protect all employees from risksand at the same time can create new risks and work problems.As far as reasonably practicable, controls other than the use of protective clothing andequipment should be used to manage risks arising from exposure to cold.Personal protective clothing and equipment should be seen as a temporary measureor a last resort to be used only when other controls may not adequately controlexposure, or are not reasonably practicable.WorkSafe Victoria Handbook Safe operation of cold storage facilities 47

14.AppendicesRisks of using protective clothing and equipmentPersonal protective clothing and equipment is not a good risk control because it:• does not eliminate or reduce the risks and dangers• may not be cost effective - often the long term monetary and employee time costsof using protective clothing and equipment are not taken into account, such as thecosts of:- selecting- storing- cleaning- fitting- medical examinations required before use- purchasing- replacing- maintaining- training employees in use and maintenance- monitoring of use and extra supervision.• only provides limited protection• will not protect employees if it is not properly selected, fitted, used, maintainedand stored• is often less effective if more than one type of personal protective clothing andequipment is used at the same time• is not always used when it should because it:- interferes with doing the job- causes discomfort and/or pain- affects vision (e.g. safety goggles, full face respirators)- interferes with hearing and talking (e.g. hearing protection, respirators)- is not used by some employees for health, physical and psychological reasons)- is difficult to use correctly if not properly supervised- interferes with employee concentration.Protective clothing and equipment can increase manual handling risks by:• making work harder that in turn may increase sweating and the risk of cold stress• restricting postures and movements making the job harder to do and increasingthe chance that protective clothing and equipment won’t be properly used (e.g.gloves can prevent getting a good grip on tools, components and materials - thisputs more physical stress on the hands, arms and shoulders).48 Handbook Safe operation of cold storage facilities WorkSafe Victoria

14.AppendicesSteps to follow before using protective clothing and equipment asa risk controlStep 1A risk assessment should be completed prior to the selection and use of any protectiveclothing and equipment and should be undertaken in consultation with those employeesand HSRs for whom the protective clothing and equipment will be provided.Step 2If the risk assessment shows that risk controls are needed, the following must beconsidered when consulting employees and the relevant HSRs who may be exposedto cold work environments:• eliminating exposure to cold• isolating employees from the cold• engineering controls that reduce employee exposure to cold• modifying or altering the systems of work to eliminate or reduce employeeexposure to cold.If these risk controls are not reasonably practicable in the short term then appropriateprotective clothing and equipment may be suitable as a temporary risk control.Elimination of Hazard/RiskYesNoReplace Hazard/Risk with something less hazardousNoYesDoes this control the Hazard?YesNoIsolate the Hazard/Risk from peopleNoYesDoes this control the Hazard?YesProtective clothing andequipment not requiredNoEngineering controls to control the Hazard/RiskNoYesDoes this control the Hazard?YesNoDo administrative changes control the Hazard/Risk?NoYesDoes this control the Hazard?YesNoGo to step 3WorkSafe Victoria Handbook Safe operation of cold storage facilities 49

14.AppendicesStep 3This checklist will help determine if protective clothing and equipment is a suitablerisk control. It identifies factors that may need to be addressed when using protectiveclothing and equipment as a risk control. Answers in a red box indicate protectiveclothing and equipment may not be a suitable primary risk control.YesNoHave employees exposed to cold and HSRs been consulted aboutthe use of protective clothing and equipment?Is there protective clothing and equipment that will effectively protectemployees from the cold?Is this protective clothing and equipment readily available?Will the protective clothing and equipment interfere with visionand communication?Will any exposed employees be unable to use the protective clothingand equipment due to physical, psychological or medical factors?Will the protective clothing and equipment interfere with thejob or task?Will using protective clothing and equipment create other risks, e.g.manual handling risks or heat stress?Step 4Take action to address any problems indicated by ticks in any of the red boxesas identified in Step 3.50 Handbook Safe operation of cold storage facilities WorkSafe Victoria

14.AppendicesStep 5Implement an effective personal protective clothing and equipment programWhen protective clothing and equipment is used as a temporary risk control aprotective clothing and equipment program should be in place and reviewed regularly.This checklist contains the essential requirements of an effective program and can beused to evaluate an existing program. Answers in a green box indicate therequirement has been satisfied.Requirement Yes No N/ADid the employer establish the program?Did the employer consult employees and HSRs whenestablishing the program?Are employees and HSRs active participants in theprogram, involved in its planning, implementation, monitoringand evaluation?Is someone designated to be responsible for the program?Does that person have the full support of employees andthe employer?Is there an effective procedure for dealing with situationswhere clothing and equipment are not being used as required?Does the procedure for selecting protective clothing andequipment include consultation?Are the following considerations met when selectingprotective clothing and equipment?• Is it comfortable and a good fit?• Does it interfere with the job?• Does it provide employees with choice?• Does it cater for differences between employees?• Does it provide adequate levels of protection?• Can it be used together with other clothing and equipment?Is there medical screening of each employee assigned towear respirators?WorkSafe Victoria Handbook Safe operation of cold storage facilities 51

14.AppendicesRequirement Yes No N/AAre employees and supervisors (including labour hire andcontractors) appropriately trained in:• the program• why the program is the only reasonably practicable riskcontrol solution at present• future risk controls which may replace the use of protectiveclothing and equipment• proper use and fitting• how to test the correct fit of the equipment(e.g. respirators)• cleaning, storage, maintenance and replacement• the limitations of the equipment and clothing• the risks, dangers, and need for protection• when, where and how the clothing and equipment isto be used• how any problems/issues with the equipment and its useare to be reported and fixed.Is clothing and equipment supplied to each employee for theiruse when reasonably practicable?Do employees get a copy of the operator’s manual for theclothing and equipment provided?Is there proper fitting and testing of clothing and equipment?Is there regular cleaning/disinfecting of clothing and equipment?Is proper no contamination storage for the clothing andequipment available?Is there periodic inspection and maintenance of the equipmentand/or replacement as required according to the instructionsof the manufacturer or supplier?Is enough employee time allocated for training, fitting,cleaning and rest breaks (if necessary) when usingsome equipment?Are there procedures for non-routine situations such asspills and leaks?Is there regular assessment of the program to ensureprocedures are being followed and employees are beingproperly protected?52 Handbook Safe operation of cold storage facilities WorkSafe Victoria

14.AppendicesStep 6Protective clothing and equipment is a temporary measure, a last resort, only to beused when other risk controls do not control exposure or are not reasonablypracticable and Steps 1-5 have been completed.If protective clothing and equipment is being used for extended periods in aworkplace, then alternative risk controls may not have been properly considered.It is the employer’s responsibility to provide protective clothing and equipment foremployees, including those from labour hire employeesStep 7A continuous improvement approach is essential. This includes annual reviews of:• changes in knowledge about the effects of cold on health• existing, and any new, risks due to changes in work processes• changes in technology and state of knowledge about risk control measuresincluding elimination, substitution, engineering and changing systems of work orwork practices• changes in technology and state of knowledge about protective clothingand equipment• the workplace’s protective clothing and equipment program.The basis for these reviews can be steps 1, 2 and 3.Factors to consider when selecting personalprotective equipment:Environmental factors to considerIn designing out risks posed by cold stress it is important to look at the workenvironment and identify the sources of cold, for example plant used, work processesand practices. In addition effects of cold on the body are influenced by environmentalfactors including:• Air temperature – how hot or cold the surrounding air is• Humidity – the moisture content in the air• Air movement – including air/wind speed and air circulation.Work related factors to considerIn addition to environmental factors which can increase the effect of cold on workersthe following factors should be considered when identifying and assessing hazardsassociated with working in cold environments:• Source of cold:- What working conditions expose employees to cold (e.g. high wind chill, wetworkplaces, poor temperature control, frequently changing temperatures)?• Nature of the work undertaken:- How does the work being done interact with or generate cold conditions (e.g.highly physical work increases sweating decreasing body temperature, vehicleoperation increases wind chill, working in confined spaces)?• Nature of materials being used in tasks:- The type of material being handled during a task will affect the risk ofskin damage.WorkSafe Victoria Handbook Safe operation of cold storage facilities 53

14.Appendices• Duration of exposure to cold:- Risks to health and safety will be increased by the length of time workers areexposed to cold (e.g. prolonged physical activity in cold or wet conditions).Worker related factors to considerWhile factors relevant to an individual worker need not exclude them from workingin a cold environment they should be identified to ensure special consideration of aworker’s need when assessing risks associated with working in cold environments.This is also important to ensure the workplace is designed appropriately toaccommodate any special considerations.• Does the person have any physical or medical health conditions that make themmore likely to be affected by cold?• Are they affected by medication, drugs or alcohol which may make them moresusceptible to cold?• Are they experienced in and acclimatised to working in cold environments?Specific factors to consider:ClothingThe following features must be considered when choosingclothing for work in chillers and freezers.1. Fit• Clothing needs to fit properly.• Clothing that is stretched tight does not insulate effectively.• Pay particular attention to knees and elbows – clothing should be looserover joints.• Inner layers need to be flexible and fit closely.• Outer layers must be large enough to be worn over the inner layerswithout stretching.• Clothing must be easily adjustable for size and with openings at the neck andwrists, under sleeves and down the front to adjust ventilation to cool down orwarm up.• If separate jackets and trousers are worn, make sure there is enough overlapbetween the jacket and the trousers to prevent cold air getting in at the waist.2. Visibility• Reflective and fluorescent colours are needed for visibility, particularly in hightraffic areas.• Having reflective and fluorescent panels and strips as part of freezer gear is muchbetter than separate vests, which can catch on equipment and cause slips, tripsand falls.3. Insulation• Clothing slows heat loss from the body, but it has to provide dry air next to the skin.• Insulation value of clothing is proportional to its thickness.• Layers provide greater insulation because they trap extra dry air between the layers.• Wearing layers allows you to cool down by removing layers as you get warmby doing physical activities.54 Handbook Safe operation of cold storage facilities WorkSafe Victoria

14.Appendices• Appropriate level of insulation will depend on the temperature in the freezer andwork being done – the colder the environment, the greater the insulation neededfrom clothing.• Intensity of the work activity will also affect the level of insulation requiredparticularly if a variety of different jobs are being done. Layers are the bestarrangement. This means that workers can remove or add layers, dependingon the work they are doing.• Clothing must be easy to put on and take off and fabrics chosen to reduce frictionbetween layers.• Fabrics used between outer and inner layers should create air spaces to provideinsulation. They should be lightweight and absorbent so they can trap water vapouraway from the skin so that it can pass through the outer layer. They need to beresilient and able to ‘spring back’ when compressed (e.g. by bending over). Wooland other fibrous materials are suitable.• The clothing should be designed so that bending over does not cause too muchcompression of the layers and therefore loss of insulation.4. Water resistance• Clothing must remain dry for the insulation properties to continue to work, requiringchanges of clothing during the work shift, particularly if moderate or heavy workis being done.• Drying rooms must be conveniently located and be big enough so that workerscan remove outer layers and dry them out.• Inner fabrics should be able to wick or draw sweat away from the skin to beabsorbed in the middle layer and breathed out through the outer layer. A numberof new fabrics are now being used for close fitting undergarments suitable forwearing under freezer jackets.5. Fasteners• Buttons do not provide enough insulation, creating openings for cold air to get in.• Zippers must be able to function in freezing temperatures and be used by cold andgloved hands.6. Durability• Clothing must be durable and strong enough to resist tears if caught on protrusions.• Torn fabric does not insulate effectively.7. Spares and cleaning• Increasing fatigue and discomfort over a shift happens because frequent entry andexit from freezers and chillers makes clothing wet and cold.• Water vapour is created by sweating while working in freezers and this turns intowater in clothing when workers move into the warm humid air outside freezers.• Increasing water in clothing reduces insulation and wet protective clothing canactually make people even colder as the clothing dries. Employees therefore needchanges of clothing whenever they get wet, either from ice melting on the clothingor from sweat as a result of physical activity.• Dirty clothing also has reduced insulation properties because it is less effective attrapping air.• Regular laundering is critical and clothing must be easily washed. This means eachemployee needs at least three sets of protective gear: one set to wear, one set tohave as spare in case clothing gets wet and one set being laundered.WorkSafe Victoria Handbook Safe operation of cold storage facilities 55

14.AppendicesBootsBoots are very important – feet are one of the most likelyparts of the body to be adversely affected by cold.The following features of boots should be consideredwhen choosing the right sort of protection.1. InsulationBoots can be lined with insulating materials such as fur or fabric or canvas or feltover-boots (to midcalf) can be used to increase insulation. Soles as well as uppersneed to be well insulated. Cold will go through a thin sole to damage feet.2. SizeLarge enough so that you can wear several pairs of socks and use an insole toimprove insulation.3. Water resistanceAbility to repel water if there is any chance that ice or water will fall on the boot. Wetboots do not provide thermal insulation.4. VentilationWell-ventilated to keep the surface next to the feet dry. If possible, boots shouldhave a vapour barrier that wicks moisture away from the feet to help keep the innersurface dry.If this is not possible, socks and insoles need to be replaced frequently and wheneverthey get wet. Boots must dry completely between shifts.5. FlexibilitySoles must be flexible, particularly if you need to operate foot controls.6. Anti-slipTread must be able to prevent slipping on wet or icy floors.7. Impact resistanceSteel capped boots should only be used as a last resort as steel conducts the coldvery well and makes feet even colder.Caps made from carbon fibre or plastics that do not go brittle in severe cold mayprovide sufficient impact resistance without conducting cold to the toes.8. Interaction with clothingBoots must fit with trouser legs effectively so that cold air cannot get in through anygaps. Trouser legs can fit under or over boots but must seal properly.56 Handbook Safe operation of cold storage facilities WorkSafe Victoria

14.AppendicesGlovesLike feet, hands are most likely to be affected by the cold. Thetypes of materials being touched can increase the impact ofcold on skin. The extremities, in particular fingers and toes, aresusceptible to cooling. Unless sufficient heat input by warmblood can be maintained, tissue temperature progressivelyfalls. Extremity blood flow is determined by energetic (requiredfor muscles activity) as well as thermoregulatory needs. When whole-body thermalbalance is challenged, peripheral vasoconstriction helps to reduce core heat lossesat the expense of peripheral tissues. With high activity more heat is available andextremity blood flow can more easily be maintained.The protection offered by hand wear and footwear in terms of reducing heat lossesis limited. When heat input to the extremity is low (e.g. with resting or low activity),the insulation required to keep hands and feet warm is very large (van Dilla, Day andSiple, 1949). The protection offered by gloves and mittens only provides retardationof cooling rate and, correspondingly, longer times to reach a critical temperature.With higher activity levels, improved protection allows warm hands and feet at lowerambient temperatures.The following features of gloves should be considered when choosing the right sortof protection.1. InsulationMittens are better than gloves for keeping hands warm. Gloves should provide thewarmth of a mitten with the manual dexterity allowed by a glove, and as such allowthe wearer to perform multiple tasks without having to remove the gloves.Good fit is essential with gloves so that work tasks can be completed. If mittens arebeing used, gloves may need to be worn underneath so that mittens can be removedfor certain jobs (e.g. using RF equipment or operating controls on forklifts).2. Interaction with clothingSleeves of jackets should fit, sealing over or under the cuff of the gloves or mittens toprevent cold air getting in. They should also be attached to jackets so that they do notget lost when removed.HeadgearA lot of heat from your body is lost through your head making wearing headgear veryimportant in freezers. The following factors should be taken into account whenchoosing headgear.1. ProtectionHeadgear must protect ears and neck and be windproof. The combination ofa knitted beanie with a hood from a freezer jacket can provide the necessary levelof protection. It also lets you remove layers to cool down when doing harder work.Balaclavas that cover your face and pull down onto the neck completely may benecessary in extreme cold or when doing sedentary work.2. Interaction with other gearHeadgear must not interfere with other types of protective gear, e.g. hearingprotection, safety glasses.WorkSafe Victoria Handbook Safe operation of cold storage facilities 57

Appendix 6 – Checklist: Anhydrous ammonia refrigerating systemsItem Regulation, Actor StandardQuestions YES orNOa.Material SafetyData Sheet(MSDS)Dangerous Goods(Storage & Handling)Regulations 2000,Reg. 438 (MSDS)Is a current MSDS for anhydrous ammonia readilyaccessible to employees and contractors on site?(Has it been reviewed within the past five years?)b.Notificationto WorkSafeVictoria ofdangerousgoods on siteDangerous Goods(Storage & Handling)Regulations 2000,Reg.506-Notification tothe AuthorityDetermine quantity of anhydrous ammonia held inthe refrigeration system.If 500 litres or more of anhydrous ammonia, hasWorkSafe been notified of the presence of thesedangerous goods?c.Planning foremergenciesDangerous Goods(Storage & Handling)Regulations 2000,Reg. 437 - Planningfor emergenciesIf 500 litres or more of anhydrous ammonia heldon site, there needs to be a written emergencymanagement plan developed in consultation withrelevant fire services.If no written plan and the quantity is less than500 litres, there should be an emergency plan asrequired under the general provisions of DangerousGoods (Storage & Handling) Regulations 2000,Regulation 444.If quantity of ammonia is 2000L or more, has theoccupier installed a fire protection system that is fullyoperation and been developed in consultation withthe relevant fire services?GuidanceGuidance: Occupier is required to have a current (no older than fi ve years)Material Safety Data Sheet (MSDS) readily accessible to any persons engagedby the occupier and any emergency services attending the site.Guidance: Quantity of ammonia in the refrigeration system is the water holdingcapacity of receiver. The volume/quantity should be stamped on the receiver.Guidance: Occupier should have a copy of the lodgement of theNotifi cation of Dangerous goods storage and handling sent to WorkSafeand/or a return receipt.Guidance: Occupier should have a written plan for dealing with emergenciesthat is currently in use and readily available.If the quantity of anhydrous ammonia is 500 litres or more, the plan needs to bedeveloped in consultation with the fi re services.Guidance: Documented plan or procedure for dealing with an anhydrousammonia leak:• wind directional devices, windsocks? (To assist in evacuating the site)• manifest and Emergency Plan available to emergency services in eventof an incident• evacuation procedures – designated evacuation zones in place• shutdown procedure for the refrigeration system in the event of an incident• plan or system that readily identifi es the function and location of valves so thatany leak or incident involving the refrigeration system can be isolated.Main isolation valves clearly labelled.Guidance: Verify a fi re protection report has been issued by the Fire Servicesand the occupier has complied with the requirements outlined within the report.(Compliance with the report can be demonstrated when the occupier is able toproduce a formal letter of compliance issued by the Fire Service).58 Handbook Safe operation of cold storage facilities WorkSafe Victoria

Checklist: Anhydrous ammonia refrigerating systems (con’t)Item Regulation, Actor StandardQuestions YES orNOd.Incidents tobe reportedDangerous GoodsAct 1985, Section 32Would an anhydrous ammonia leak be reported topolice or relevant fire authority as required underDangerous Goods Act 1985?Occupational Healthand Safety Act 2004,Section 38Would the employer notify WorkSafe in the event ofan ammonia leak that results in injury to any personthat requires medical treatment as defined in Section38 of the Occupational Health and Safety Act 2004GuidanceGuidance: Occupier should have formal procedures outlined within theemergency plan to meet this reporting requirement.Guidance: Occupier should have formal procedures outlined within theemergency plan to meet this reporting requirement.WorkSafe Victoria Handbook Safe operation of cold storage facilities 59

Checklist: Anhydrous ammonia refrigerating systems (con’t)Item Regulation, Actor StandardQuestions YES orNOe.Maintenancesystems inplace forammoniarefrigerationsystemDangerous Goods(Storage & Handling)Regulations 2000,Reg. 407 - Generalduty to control risk.Has the occupier implemented adequate risk-controlmeasures associated with the safe storage andhandling of anhydrous ammonia within therefrigeration system?Dangerous Goods(Storage & Handling)Regulations 2000,Reg. 418 - Structureand plant – conditionand repairIs there a formal and effective preventativemaintenance system or program in place for theanhydrous ammonia refrigeration plant andequipment?Is the anhydrous ammonia refrigeration plant and thepreventative maintenance system operated in-houseor by external contractors or combination of both?Are those responsible for the maintenance andoperation of the anhydrous ammonia refrigerationplant and equipment suitably trained?GuidanceGuidance: Occupier is required to demonstrate that there are adequate riskcontrols in place. This can be achieved by conducting a formal self-assessmentagainst AS 1677 Refrigeration systems.Refrigeration systems. Part 1: Refrigerant classifi cationsRefrigeration systems. Part 2: Safety requirements for fi xed applicationsNote: If other codes or standards are used they need to demonstratecompliance to an equivalent level of AS 1677Guidance: Occupier is required to demonstrate that there is an effectivemaintenance system in place which is formally recorded within a register, andclearly lists and identifi es safety items that are critical to the safe operation of therefrigeration system such as:• safety relief valves• ventilation systems• detectors (if provided)• critical operating valves• sensors fi tted to level indicators• high and low level alarms• pressure vessel inspected. Refer: AS3788:2006 Pressure Equipment – InService Inspection• intrinsically safe electrical equipment and wiring (where detectors are notprovided refer: AS1677 Part 2 clause 4.7.6)Occupier should be able to demonstrate that the appropriate maintenanceregime is being provided on all items identifi ed in the register.Guidance: Occupier has formal records which confi rm employees and/orcontractors responsible for the operation and maintenance of the anhydrousammonia refrigeration plant and equipment at the workplace have receivedappropriate training.60 Handbook Safe operation of cold storage facilities WorkSafe Victoria

Checklist: Anhydrous ammonia refrigerating systems (con’t)Item Regulation, Actor StandardQuestions YES orNOGuidanceIs there a copy of the operating and maintenancemanual for the refrigeration plant and equipment onsite and readily accessible? (Refer: AS 1677Refrigeration systems Part 2 Safety requirements forfixed applications Clause 6.2.1)Guidance: The Occupier has a copy of the operating and maintenance manualas required under the provisions of Dangerous Goods (Storage & Handling)Regulations 2000, Reg. 402.Formal safe work procedures:• identify and control the risks associated with the safe operation andmaintenance of the anhydrous ammonia plant and equipment• require that a Safe Work Method (SWM) is undertaken prior to anymaintenance work• have one or more permit systems in place for maintenance work (e.g. hotwork, confi ned space entry).Are premises and vessels adequately placarded? Guidance: There must be outer warning placarding “HAZCHEM” provided atevery road vehicle entry where the quantity of anhydrous ammonia on site is 500litres or more. Refer: Dangerous Goods (Storage & Handling) Regulations 2000,Reg. 429.Where capacity of the bulk container (receiver) is greater than 500 litres,appropriate placarding must be provided on the vessel.Refer: Dangerous Goods (Storage & Handling) Regulations 2000, Reg. 430.Is there adequate first aid facilities and emergencyequipment such as safety shower/eye wash stationclose to the refrigeration plant room?Guidance: Hazards and risks associated within the storage and any handlingof corrosive materials such as anhydrous ammonia must be identifi ed andappropriately controlled. The level of exposure to corrosive materials such asanhydrous ammonia during charging of and maintenance to the refrigerationplant and equipment will determine what risk control measures, such asemergency and medical equipment, may be required (e.g. eye wash, safetyshower, fi rst aid facilities).Refer: Dangerous Goods (Storage and Handling) Regulations 2000, (Reg. 405)f.Site andinstallation ofrefrigerationsystemDangerous Goods(Storage & Handling)Regulations 2000,Reg. 425 -Ventilation andatmosphericemissionsIf the refrigeration plant and equipment is locatedwithin a room/building, appropriate natural ormechanical ventilation will be required?Guidance: Refrigeration plant and equipment located indoors needs to beeither naturally or mechanically ventilated. (For specifi c ventilation rates referto Table 4.1 AS 1677 Refrigreration systems Part 2: Safety requirements forfi xed applications).WorkSafe Victoria Handbook Safe operation of cold storage facilities 61

Checklist: Anhydrous ammonia refrigerating systems (con’t)Item Regulation, Actor StandardQuestions YES orNOGuidanceg.HazardouszonesIf the system is located in the open, are there anypotential ignitions sources within in 1.5 metres of therefrigeration plant and equipment?Guidance: If there are ignition sources within 1.5 metres of the refrigerationplant then a hazardous zone risk assessment needs to be conducted as perAS 2430. Classifi cation of hazardous areas.Is the system is located in a room or space? Guidance: Then all electrics in that room or spaced should be suitable tooperate in a zoned hazardous area. AS 2430. Classifi cation of hazardous areas.h.Site andinstallation ofrefrigerationsystemDangerous Goods(Storage & Handling)Regulations 2000AS 1677RefrigerationsystemsAS 1345Identification ofcontents of pipesIs refrigerant piping protected againstvehicle impact?Is pipe-work appropriately marked accordingto AS1345?Guidance: Is refrigerant plant, equipment and piping appropriately protectedfrom impact damage by vehicles or mobile plant etc. Refer: Dangerous Goods(Storage & Handling) Regulations, Reg 421.Guidance: Liquid and vapour pipe lines must be capable of being readilyidentifi ed and marked or colour coded in the appropriate colours asper AS 1345 .Colours as defi ned in AS 1345:Background: Yellow-ochre (Straw, Sand, sandstone, Raffi a, Biscuit)Writing: BlackDirectional arrow showing fl ow directionAMMONIAIf the refrigeration system is located within anenclosed room or space where people may enterand work is there an audible and visible evacuationalarm system?Guidance: Where persons are required to work near evaporators (containinganhydrous ammonia) the occupier should have one or more gas detectorsinstalled in the work area to provide early warning in the event of a refrigerantleak and before persons are exposed to dangerous concentrations of therefrigerant anhydrous ammonia.Note: There are potential health risks for asphyxiation to occur where thereis a leakage of gas. Refer: AS Refrigerating systems 1677 Part2: Safetyrequirements for fi xed applications, Clause 4.8.1.62 Handbook Safe operation of cold storage facilities WorkSafe Victoria

Checklist: Anhydrous ammonia refrigerating systems (con’t)Item Regulation, Actor StandardQuestions YES orNO• Is personal protective equipment (PPE) provided?• Is the PPE maintained? (Breathing apparatus(BA) set if required)• Is PPE readily available?• Is there PPE appropriately stored?• Are there appropriate records to verifymaintenance of PPE?Are relevant people trained and currently competentin the use of the PPE? (BA set)i.Induction,information,training andsupervisionDangerous Goods(Storage & Handling)Regulations 2000,Reg. 402.Are people involved with daily operation of theanhydrous ammonia refrigeration system suitablytrained and aware of the hazards and risksassociated with the refrigeration plant andequipment and the refrigerant (anhydrousammonia) used?GuidanceGuidance: For anhydrous ammonia amounts;• ≤ 225kg 1 respirator required• > 225kg’s 2 respirator required• 900kg’s 1 self-contained BA with effective life of 25mins + PPEto AS2022 required including maintenance of equipmentGuidance: Suitable training must be provided to those who may be required touse a BA set and emergency drills should be conducted to review and ensureemergency procedures are adequate.Guidance: Occupier must ensure employees and contractors involved in theoperation and maintenance of the refrigeration plant and equipment havereceived appropriate information, instruction and training. Records verifyinginduction or any other hazard or competency based training has been providedshould be maintained with records of safety and tool box meetings.WorkSafe Victoria Handbook Safe operation of cold storage facilities 63

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